Composites of polyurethanes and vinyl polymers

Claim 2

A non-cellular polyurethane/vinyl polymer composite article which (I) has a density of at least about 1 g/cc, (II) has a percent elongation of less than about 100 and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article; said article resulting after admixture of the components of a composition which comprises: (A) a liquid polyol, or mixture of such polyols having from about 2 to about 8 hydroxyl groups and an OH equivalent weight of from about 30 to about 250; (B) an organic polyisocyanate or mixture of such polyisocyanates having an NCO equivalent weight of less than about 300, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate or polyisocyanate mixture has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) of a modifier substance free from groups reactive with Components (A), (B), or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any absorbed or occluded water and will not decompose at a temperature below the maximum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers, said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram/° C.; and (4) mixtures thereof; and wherein Components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1 and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound, then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F), it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate.

Claim 3

The composite articles of claim 1 wherein Components (A) and (B) are essentially free from ethylenic unsaturation and are present in quantities such that the NCO:OH ratio is from about 0.95:1 to about 1.2:1 and the equivalent weight of Component (A) is from about 50 to about 200 and the equivalent weight of Component (B) is less than about 250 and wherein Component (C) is essentially free of groups reactive with Components (A) or (B), has an atmospheric boiling point above about 100° C. and is present in quantities of from about 20% to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D) and (E).

Claim 4

The composite articles of claim 2 wherein Component (C) has an atmospheric boiling point above about 120° C.

Claim 5

The composite articles of claim 3 wherein Component (A) is an adduct of glycerine, trimethylolpropane, pentaerythirtol sucrose or mixtures thereof with propylene oxide, ethylene oxide or mixtures thereof.

Claim 6

The composite articles of claim 4 wherein Component (A) is an adduct of glycerine with propylene oxide.

Claim 7

The composite articles of claim 3 wherein Component (C) contains styrene.

Claim 8

The composite articles of claim 3 wherein Component (C) contains a tertiary amino-containing vinyl compound.

Claim 9

The composite articles of claim 3 wherein Component (A) contains an amine initiated polyol.

Claim 10

A process for preparing a non-cellular polyurethane/vinyl polymer composite article which (I) has a density of at least about 1 g/cc, (II) has a percent elongation of less than about 100 and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article, which process comprises: (I) admixing the components of a composition comprising (A) a liquid polyol, or mixture of such polyols, having from about 2 to about 8 hydroxyl groups and an OH equivalent weight of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 300, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) of a modifier substance free from groups reactive with Components (A), (B) or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any adsorbed or occuluded water and will not decompose at a temperature below the mazimum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers; said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram/° C.; and (4) mixtures thereof; and wherein components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1 and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound, then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F), it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate. (II) pouring the admixed composition into a suitable mold wherein said composition solidifies within about 15 minutes to a solid having the aforesaid density and elongation; and (III) subsequently demolding the resultant article from the mold.

Claim 11

A process for preparing a non-cellular polyurethane/vinyl polymer composite article which (I) has a density of at least about 1 g/cc, (II) has a percent elongation of less than about 100 and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article, which process comprises: (I) admixing the components of a composition comprising (A) a liquid polyol, or mixture of such polyols, having from about 2 to about 8 hydroxyl groups and an OH equivalent weight of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 300, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) of a modifier substance free from groups reactive with Components (A), (B) or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any adsorbed or occuluded water and will not decompose at a temperature below the mazimum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers; said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02 inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram/° C.; and (4) mixtures thereof; and wherein components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1 and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound, then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F), it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate. (II) pouring the admixed composition into a suitable mold wherein said composition solidifies within about 15 minutes to a solid having the aforesaid density and elongation; and (III) subsequently demolding the resultant article from the mold.

Claim 12

The process of claim 9 wherein Components (A) and (B) are essentially free from ethylenic unsaturation and are present in quantities such that the NCO:OH ratio is from about 0.95:1 to about 1.2:1 and the equivalent weight of Component (A) is from about 50 to about 200 and the equivalent weight of Component (B) is less than about 250 and wherein Component (C) is essentially free of groups reactive with Components (A) or (B), had an atmospheric boiling point above about 100° C. and is present in quantities of from about 20% to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D) and (E).

Claim 13

The process of claim 10 wherein Component (C) has an atmospheric boiling point above about 120° C.

Claim 14

The process of claim 11 wherein Component (A) is an adduct of glycerine, trimethylolpropane, pentaerythritol, sucrose or mixtures thereof with propylene oxide, ethylene oxide or mixtures thereof.

Claim 15

The process of claim 12 wherein Component (A) is an adduct of glycerine with propylene oxide.

Claim 16

The process of claim 11 wherein Component (C) contains styrene.

Claim 17

The process of claim 11 wherein Component (C) contains a tertiary amino-containing vinyl compound.

Claim 18

The process of claim 11 wherein Component (A) contains an amine initiated polyol.

Claim 19

A cellular polyurethane/vinyl polymer composite article which (I) has substantially uniform cells, (II) has a substantially uniform density of less than 1 g/cc and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article; said article resulting after admixture of the components of a composition which comprises: (A) a liquid polyol, or mixtures of such polyols, having from about 2 to about 8 hydroxyl groups and an OH equivalent weight of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 250, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) of a modifier substance free from groups reactive with Components (A), (B), or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any absorbed or occluded water and will not decompose at a temperature below the maximum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers, said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02-inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram/° C.; and (4) mixtures thereof; (G) a foam-forming system which comprises (1) a foaming agent selected from the group consisting of (a) low boiling vaporizable organic liquids having a boiling point below the reaction exotherm temperature; (b) substances which decompose theremally to release CO 2 or release water vapor at the exotherm temperature; (c) a solid particulate substance which will pass through a 2 mm square opening and which has a surface area of at least 0.8 m 2 /gram; (d) an inorganic metal hydrate characterized as having a solubility in anhydrous ethyl alcohol of less than about 1.2 grams per 100 grams and a weight loss of at least 5% when subjected to a temperature of 115° C. for 30 minutes at atmospheric pressure; (e) water; (f) mixtures thereof; and (2) a cell control agent; wherein Components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1, Component (G-1) is present in quantities sufficient to provide the desired density and Component (G-2) is present in quantities sufficient to provide substantially uniform cells; and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F),, it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate; (g) that when Comopnent (G-1-c) or (G-1-d) is employed as the blowing agent, Component (G-2) is not required.

Claim 20

A cellular polyurethane/vinyl polymer composite article which (I) has substantially uniform cells, (II) has a substantially uniform density of less than 1 g/cc and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article; said article resulting after admixture of the components of a composition which comprises: (A) a liquid polyol, or mixtures of such polyols, having from about 2 to about 8 hydroxyl groups and an OH equivalent weight of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 250, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) of a modifier substance free from groups reactive with Components (A), (B), or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any absorbed or occluded water and will not decompose at a temperature below the maximum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers, said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02-inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram/° C.; and (4) mixtures thereof; (G) a foam-forming system which comprises (1) a foaming agent selected from the group consisting of (a) low boiling vaporizable organic liquids having a boiling point below the reaction exotherm temperature; (b) substances which decompose theremally to release CO 2 or release water vapor at the exotherm temperature; (c) a solid particulate substance which will pass through a 2 mm square opening and which has a surface area of at least 0.8 m 2 /gram; (d) an inorganic metal hydrate characterized as having a solubility in anhydrous ethyl alcohol of less than about 1.2 grams per 100 grams and a weight loss of at least 5% when subjected to a temperature of 115° C. for 30 minutes at atmospheric pressure; (e) water; (f) mixtures thereof; and (2) a cell control agent; wherein Components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1, Component (G-1) is present in quantities sufficient to provide the desired density and Component (G-2) is present in quantities sufficient to provide substantially uniform cells; and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F),, it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate; (g) that when Comopnent (G-1-c) or (G-1-d) is employed as the blowing agent, Component (G-2) is not required.

Claim 21

The composite articles of claim 17 wherein Components (A) and (B) are essentially free from ethylenic unsaturation and are present in quantities such that the NCO:OH ratio is from about 0.95:1 to about 1.2:1 and the equivalent weight of Component (A) is from about 50 to about 200 and the equivalent weight of Component (B) is less than about 250 and wherein Component (C) is essentially free of groups reactive with Components (A) or (B), has an atmospheric boiling point above about 100° C. and is present in quantities of from about 20% to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D) and (E).

Claim 22

The composite articles of claim 18 wherein Component (C) has an atmospheric boiling point above about 120° C.

Claim 23

The composite articles of claim 19 wherein Component (A) is an adduct of glycerine, trimethylolpropane, pentaerythritol, sucrose or mixtures thereof with propylene oxide, ethylene oxide or mixtures thereof.

Claim 24

The composite articles of claim 19 wherein Component (A) is an adduct of glycerine with propylene oxide.

Claim 25

The composite articles of claim 19 wherein Component (C) contains styrene.

Claim 26

The composite articles of claim 19 wherein Component (C) contains a tertiary amino-containing vinyl compound.

Claim 27

The composite articles of claim 19 wherein Component (A) contains an amine initiated polyol.

Claim 28

A process for preparing a cellular polyurethane/vinyl polymer composite article which (I) has substantially uniform cells, (II) has a substantially uniform density of less than 1 g/cc and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article, which process comprises: (I) admixing the components of a composition comprising (A) a liquid polyol, or mixture of such polyols having from about 2 to about 8 hydroxyl groups and an OH equivalent wieght of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 250, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) or a modifier substance free from groups reactive with Components (A), (B), or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any absorbed or occluded water and will not decompose at a temperature below the maximum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers, said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02-inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram° C.; and (4) mixtures thereof; (G) a foam-forming system which comprises (1) a foaming agent selected from the group consisting of (a) low boiling vaporizable organic liquids having a boiling point below the reaction exotherm temperature; (b) substances which decompose thermally to release CO 2 or release water vapor at the exotherm temperature; (c) a solid particulate substance which will pass through a 2 mm square opening and which has a surface area of at least 0.8 2 gram; (d) an inorganic metal hydrate characterized as having a solubility in anhydrous ethyl alcohol of less than about 1.2 grams per 100 grams and a weight loss of at least 5% when subjected to a temperature of 155° C. for 30 minutes at atmospheric pressure; (e) water (f) mixtures thereof; and (2) a cell control agent; and wherein Components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1, Component (G-1) is present in quantities sufficient to provide the desired density and Component (G-2) is present in quantities sufficient to provide substantially uniform cells; and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F), it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate; (g) that when Component (G-1-c) or (G-1-d) is employed as the blowing agent, Component (G-2) is not required; (II) pouring the admixed composition into a suitable mold wherein said composition solidifies within about 15 minutes to a solid having the aforesaid density; and (III) subsequently substantially demolding the resultant article from the mold.

Claim 29

A process for preparing a cellular polyurethane/vinyl polymer composite article which (I) has substantially uniform cells, (II) has a substantially uniform density of less than 1 g/cc and (III) can be demolded and used for its intended purpose, after cooling to a suitable handling temperature, within a period of about 15 minutes or less without the application of an external source of heat after admixture of the components forming said article, which process comprises: (I) admixing the components of a composition comprising (A) a liquid polyol, or mixture of such polyols having from about 2 to about 8 hydroxyl groups and an OH equivalent wieght of from about 30 to about 250; (B) an organic polyisocyanate having an NCO equivalent weight of less than about 250, with the proviso that when Component (A) has an average of about 2 hydroxyl groups per molecule, said polyisocyanate has an average of at least about 2.5 NCO groups per molecule; (C) from at least about 15% to less than about 65% by weight of the combined weight of Components (A), (B), (C), (D) and (E) of a polymerizable ethylenically unsaturated monomer having an atmospheric boiling point above about 80° C. or mixtures of such monomers; (D) an effective quantity of a catalyst for polymerizing Component (C); (e) an effective quantity of a catalyst for urethane formation such that the composition reaches an exotherm temperature of at least about 80° C.; and (F) from 0 to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D), (E) and (F) or a modifier substance free from groups reactive with Components (A), (B), or (C) at the conditions employed herein, said modifier substances being selected from the group consisting of (1) liquid substances having an atmospheric boiling point of at least about 150° C.; (2) solid substances having a surface area of less than about 0.8 m 2 /gram and a particle size such that said substance will pass through a 1/4-inch square opening is substantially free of any absorbed or occluded water and will not decompose at a temperature below the maximum exotherm temperature generated by the urethane forming reaction; (3) polymers of one or more ethylenically unsaturated monomers, said polymers having (a) a molecular weight such that the polymer has a grease melt flow index as determined with a 0.02-inch orifice employing a total weight of 2160 grams at 80° C. of from about 1 to about 250 decigrams/minute; (b) a solubility parameter of at least about 8; (c) and a specific heat of at least about 0.35 calories/gram° C.; and (4) mixtures thereof; (G) a foam-forming system which comprises (1) a foaming agent selected from the group consisting of (a) low boiling vaporizable organic liquids having a boiling point below the reaction exotherm temperature; (b) substances which decompose thermally to release CO 2 or release water vapor at the exotherm temperature; (c) a solid particulate substance which will pass through a 2 mm square opening and which has a surface area of at least 0.8 2 gram; (d) an inorganic metal hydrate characterized as having a solubility in anhydrous ethyl alcohol of less than about 1.2 grams per 100 grams and a weight loss of at least 5% when subjected to a temperature of 155° C. for 30 minutes at atmospheric pressure; (e) water (f) mixtures thereof; and (2) a cell control agent; and wherein Components (A) and (B) are present in quantities such that the NCO:OH equivalent ratio is from about 0.75:1 to about 1.5:1, Component (G-1) is present in quantities sufficient to provide the desired density and Component (G-2) is present in quantities sufficient to provide substantially uniform cells; and with the following provisos: (a) that the urethane exotherm temperature does not greatly exceed the boiling point of the monomer or mixture of monomers employed as Component (C); (b) that when Component (A) is an amine initiated polyol, Component (E) need not be present; (c) that when Component (B) is an aromatic polyisocyanate and Component (C) contains a tertiary amino vinyl compound then Component (E) may be omitted; (d) that the combined quantity of Components (C) and (F) be less than about 60% by weight based upon the combined weight of Components (A), (B), (C) and (F); (e) that when Component (F-3) is employed as Component (F), it is employed in quantities of ≦20% by weight of the combined quantities of Components (A), (B) and (F); (f) that when Component (E) contains only a tertiary aliphatic amine, Component (B) must contain an aromatic polyisocyanate; (g) that when Component (G-1-c) or (G-1-d) is employed as the blowing agent, Component (G-2) is not required; (II) pouring the admixed composition into a suitable mold wherein said composition solidifies within about 15 minutes to a solid having the aforesaid density; and (III) subsequently substantially demolding the resultant article from the mold.

Claim 30

The process of claim 25 wherein Components (A) and (B) are essentially free from ethylenic unsaturation and are present in quantities such that the NCO:OH ratio is from about 0.95:1 to about 1.2:1 and the equivalent weight of Component (A) is from about 50 to about 200 and the equivalent weight of Component (B) is less than about 250 and wherein Component (C) is essentially free of groups reactive with Components (A) or (B), has an atmospheric boiling point above about 100° C. and is present in quantities of from about 20% to about 50% by weight based upon the combined weight of Components (A), (B), (C), (D) and (E).

Claim 31

The process of claim 26 wherein Component (C) has an atmospheric boiling point above about 120° C.

Claim 32

The process of claim 27 wherein Component (A) is an adduct of glycerine, trimethylolpropane, pentaerythritol, sucrose or mixtures thereof with propylene oxide, ethylene oxide or mixtures thereof.

Claim 33

The process of claim 27 wherein Component (A) is an adduct of glycerine with propylene oxide.

Claim 34

The process of claim 27 wherein Component (C) contains styrene.

Claim 35

The process of claim 27 wherein Component (C) contains a tertiary amino-containing vinyl compound.

Claim 36

The process of claim 27 wherein Component (A) contains an amine initiated polyol.